Fuel tank and method for making same

ABSTRACT

A fuel tank having a top shell with an outwardly extending flange about its outer periphery and a bottom shell also having an outwardly extending flange about its outer periphery. The top and bottom shells are dimensioned so that, with the top shell positioned on top of the bottom shell, an outer peripheral portion of the top shell flange flatly abuts against an outer peripheral portion of the bottom shell flange and these outer peripheral portions are secured together. A component support has an outer edge portion sandwiched in between the flanges at a position spaced inwardly from the flange outer peripheral portions. The flanges and the outer edge portion of the component support are then bent to a plane oblique to the component support to thereby mechanically lock the outer edge portion of the component support and the flanges together.

BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention relates generally to fuel tanks and methods for making fuel tanks.

II. Description of Material Art

Fuel tanks of the type used in automotive vehicles typically include a top shell having an outwardly extending flange about its outer periphery as well as a bottom shell also having an outwardly extending flange about its outer periphery. With the top shell positioned on top of the bottom shell, the flanges abut and are secured together so that the top and bottom shells form a fuel chamber.

Most fuel tanks for modern day automotive vehicles include additional components within the interior of the fuel tank. Such components include, for example, a fuel gauge as well as other components.

In order to mount these fuel components within the interior of the fuel tank fuel chamber, a component support is typically disposed in between the top shell and bottom shell of the fuel tank so that an outer edge portion of the component support is sandwiched in between the outwardly extending flanges from the top shell and bottom shell. The top shell and bottom shell are then secured together by welding the top shell flange, outer edge portion of the component support and the bottom shell flange together. In doing so, the weld ideally provides a fluid-tight attachment between the top shell and bottom shell.

One disadvantage of these previously known fuel tanks, however, is that it is necessary to weld through three thicknesses of metal, i.e. the top shell flange, component support outer edge portion and the bottom shell flange, in order to seal the top shell and bottom shell together. Such welding through three thicknesses of metal not only increases the power consumption for the welding operation, but also increases manufacturing cycle time.

A still further disadvantage of these previously known fuel tanks is that it was oftentimes necessary to attach brackets to the fuel tank to facilitate subsequent mounting of the fuel tank in a vehicle or other device. Such mounting brackets were typically welded to the fuel tank after assembly of the fuel tank which increased the overall manufacturing cost for the fuel tank.

SUMMARY OF THE INVENTION

The present invention provides a fuel tank as well as method for making the same which overcomes the above-mentioned disadvantages of the previously known fuel tanks.

In brief, the fuel tank of the present invention includes a top shell having an outwardly extending flange about its outer periphery. Similarly, a bottom shell also has an outwardly extending flange formed about its outer periphery.

The top and bottom shells are dimensioned so that, with the top shell positioned on top of the bottom shell, an outer peripheral portion of the top shell flange flatly abuts against an outer peripheral portion of the bottom shell flange. These outer peripheral portions of the flanges, furthermore, are secured together by welding, crimping or other conventional means to form a fuel storage chamber between the top shell and the bottom shell.

A component support includes an outer edge portion that is sandwiched in between the top shell flange and bottom shell flange at a position spaced inwardly from the flange outer peripheral portions prior to the welding operation. The flanges and outer edge portion of the component support are then bent to a plane oblique to a plane of the component support to thereby mechanically lock the outer edge portion of the component support and the top and bottom shell flanges together.

Since only the outer peripheral portion of the top shell and bottom shell flanges are secured together by welding, crimping or the like, the energy necessary to secure the top and bottom shells together is minimized as well as the manufacturing cycle time. In a modification of the invention, the component support includes a portion which extends outwardly from the top and bottom shell flanges. That portion may then be used to form a bracket for use in mounting the fuel tank in an automotive vehicle or other device to which the fuel tank is mounted.

BRIEF DESCRIPTION OF THE DRAWING

A better understanding of the present invention will be had upon reference to the following detailed description when read in conjunction with the accompanying drawing, wherein like reference characters refer to like parts throughout the several views, and in which:

FIG. 1 is an elevational view illustrating a preferred embodiment of the present invention; and

FIG. 2A-FIG. 2D are all fragmentary sectional views illustrating the construction of the fuel tank of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE PRESENT INVENTION

With reference first to FIG. 1, a preferred embodiment of a fuel tank 10 in accordance with the present invention is shown. The fuel tank 10 includes a top shell 12 which is positioned on top of a bottom shell 14 to form a fuel chamber 16 (FIG. 2) between the top shell 12 and the bottom shell 14. The fuel tank 10 shown in FIG. 1 is of the type used in automotive vehicles although the fuel tank 10 may be used in any application where fuel storage is required.

With reference now to FIGS. 2A-2D, during the manufacture of the fuel tank 10, the top shell 12 includes an outwardly extending flange 18 formed about its outer periphery. Similarly, the bottom shell 14 also includes an outwardly extending flange 20 about its outer periphery. The top shell 12 and bottom shell 14 as well as their respective flanges 18 and 20, furthermore, are dimensioned so that as the top shell 12 is positioned on top of the bottom shell 14 as shown in FIG. 2B, an outer peripheral portion 22 of the top shell flange 18 flatly abuts against an outer peripheral portion 24 of the bottom shell flange 20.

A component support 26 is positioned within an interior fuel chamber 16 of the fuel tank 10. This component support 26 includes an outer edge portion 28 which is sandwiched in between the top shell flange 18 and the bottom shell flange 20 at a position spaced inwardly from the outer peripheral portions 22 and 24 of the top shell flange 18 and bottom shell flange 20, respectively, as best shown in FIG. 2B. This component support 26 is used to support fuel components 30, e.g. a fuel gauge, within the interior fuel chamber 16 of the fuel tank 10.

With reference now particularly to FIG. 2C, with the top shell 12 positioned on the bottom shell 14 and the component support 26 positioned within the interior chamber 16 of the fuel tank, the outer peripheral portions 22 and 24 of the top shell flange 18 and bottom shell flange 20 are then secured together by any conventional means, such as a weld 32 which extends continuously around the fuel tank 10 to seal the top and bottom shell 12 and 14 together. Other means, however, such as crimping, adhesive, etc., may also be used to secure the outer peripheral portions 22 and 24 of the flanges 18 and 20, respectively, together without deviation from the spirit or scope of the invention.

After the outer peripheral portions 22 and 24 of the flanges 18 and 20, respectively, have been secured together, the flanges 18 and 20 are then bent as shown in FIG. 2D to a plane 34 that is oblique to a plane 36 of the component support 26. In doing so, the top shell flange 18 and bottom shell flange 20 mechanically lock the outer edge portion 28 of the component support 26 to the top and bottom shells 12 and 14, thus rigidly securing the component support 26 to the top and bottom shells 12 and 14 within the interior chamber 16 of the fuel tank 10.

A primary advantage of the present invention is that it is only necessary to attach two layers of material, typically metal, together, i.e. the flange outer peripheral portion 22 and flange 20 outer peripheral portion 24, in order to fluidly seal the top shell 12 to the bottom shell 14. This, in turn, reduces both energy cost as well as manufacturing cycle time.

With reference now again to FIG. 1, optionally the component support 26 includes one or more brackets 38 which extend outwardly from the top shell flange 18 and bottom shell flange 20. By providing the brackets 38 as an integral piece of the component support 26, the previously known necessity of welding or otherwise securing brackets to the fuel tank 10 after assembly is eliminated.

From the foregoing, it can be seen that the present invention provides a simple and yet effective fuel tank as well as a method for manufacturing the fuel tank that is inexpensive and yet effective in operation. Having described my invention, however, many modifications thereto will become apparent to those skilled in the art to which it pertains without deviation from the spirit of the invention as defined by the scope of the appended claims. 

1. A fuel tank construction comprising: a top shell having an outwardly extending flange about its outer periphery, a bottom shell having an outwardly extending flange about its outer periphery, said top and bottom shells being dimensioned such that with said top shell being positioned on top of said bottom shell an outer peripheral portion of said top shell flange flatly abuts against an outer peripheral portion of said bottom shell flange, said outer peripheral portions of said flanges being secured together, said top and bottom shell forming a fuel storage chamber therebetween, a component support having an outer edge portion sandwiched in between said flanges at a position spaced inwardly from said flange outer peripheral portions, said flanges and said outer edge portion of said component support being bent to a plane oblique to a plane of said component support to thereby mechanically lock said outer edge portion of said component support and said flanges together.
 2. The fuel tank as defined in claim 1 wherein said outer peripheral portions of said flanges are welded together.
 3. The fuel tank as defined in claim 1 wherein said top shell, said bottom shell and said component support are constructed of a metal.
 4. The fuel tank as defined in claim 1 wherein a portion of said component support extends outwardly from said flanges and forms a mounting bracket.
 5. A fuel tank construction comprising: a top shell having an outwardly extending flange about its outer periphery, a bottom shell having an outwardly extending flange about its outer periphery, said top and bottom shells being dimensioned such that with said top shell being positioned on top of said bottom shell an outer peripheral portion of said top shell flange flatly abuts against an outer peripheral portion of said bottom shell flange, said outer peripheral portions of said flanges being secured together, said top and bottom shell forming a fuel storage chamber therebetween, a component support having an outer edge portion sandwiched in between said flanges at a position spaced inwardly from said flange outer peripheral portions, said flanges and said outer edge portion of said component support being secured together by bending said flanges and said outer edge portion of said component support to a plane oblique to a plane of said component support to thereby mechanically lock said outer edge portion of said component support and said flanges together.
 6. The fuel tank as defined in claim 5 wherein said outer peripheral portions of said flanges are welded together.
 7. The fuel tank as defined in claim 5 wherein said top shell, said bottom shell and said component support are constructed of a metal.
 8. The fuel tank as defined in claim 5 wherein a portion of said component support extends outwardly from said flanges and forms a mounting bracket.
 9. A method of constructing a fuel tank construction comprising: forming a top shell having an outwardly extending flange about its outer periphery, forming a bottom shell having an outwardly extending flange about its outer periphery, positioning said top and bottom shells together so that with said top shell being positioned on top of said bottom shell an outer peripheral portion of said top shell flange flatly abuts against an outer peripheral portion of said bottom shell flange, securing said outer peripheral portions of said flanges being together so that said top and bottom shell form a fuel storage chamber therebetween, positioning an outer edge portion of a component in between said flanges at a position spaced inwardly from said flange outer peripheral portions, bending said flanges and said outer edge portion of said component support to a plane oblique to a plane of said component support to thereby mechanically lock said outer edge portion of said component support and said flanges together.
 10. The method as defined in claim 9 wherein said securing step comprises welding.
 11. The method as defined in claim 9 wherein said top shell, said bottom shell and said component support are constructed of a metal. 